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Modular supply concept for electrolyzers

Modular supply concept for electrolyzers A modular solution consisting of AC/DC converters is ideal for supplying electrolysis cells with direct current. Find out in our white paper how a modular supply concept simplifies maintenance and has a beneficial effect on the availability and service life of electrolysis stacks.

AC/DC converters of the CHARX power system in the electrolyzer

The challenge

Person installing DC rectifier module in the control cabinet

Scalable alternative to monolithic large-scale converters

Common to all electrolyzers is the need for direct current. Alternating current from the public power grid is initially rectified by AC/DC converters. Often, monolithic large converters are still used, which are installed individually for the respective electrolysis plant.

An alternative is a modular supply concept based on our AC/DC converters in the CHARX power system. With the wide range of possible topologies that can be implemented with the aid of modular AC/DC converters, the concept is suitable for use in pilot systems and large electrolyzers alike.

Solution

Control cabinets in an electrolysis plant

Control cabinet with zoom on T-LOX terminal blocks

High efficiency

CHARX AC/DC converters based on IGBT or SiC technology are used for the DC power supply. With an efficiency of up to 97 percent, it is significantly superior to monolithic converters. With a controllable DC output voltage range of 30 to 1000 V, they can be adapted to the operating voltage of different electrolysis stacks. Both the operating voltage and the output current can be ramped up slowly via a ramp function. The converters have an internal electrical isolation between the AC and DC grids. This is vitally important for the design of the power supply of many electrolyzers.

Condition monitoring that can be easily integrated

Our devices from the PLCnext Control family are ideal for control applications. Library elements that simplify programming are available for the controllers. They enable flexible control of voltage and current and easy integration of data points for condition monitoring. Furthermore, the CHARX converters are also equipped with an openly accessible bus system.

Structure of standardized control cabinets

Because of the 19" rack design, the modules fit in every control cabinet that is standardized for 19" racks. The modules adapt optimally to the power requirements of the respective electrolysis modules. Installing the power cables is particularly easy with our T-LOX terminal blocks. This eliminates the need for individual backplane planning. In addition, you can add additional modules quickly and easily at a later date. Operation without a backplane also facilitates the natural air flow and therefore the heat dissipation of the devices. Service and maintenance work is simplified by the handiness and effortless installation of the devices.

Graphical structure of a redundancy application in the event of a rectifier module defect

Increased availability

Modular rectifier concepts increase availability in electrolysis applications. If a defect occurs in a large monolithic converter, the entire electrolysis plant fails. However, with a modular approach, only the portion of the affected power module is lost. Depending on the system design, the failure of a power module can even be fully compensated.

Your advantages Learn more about the modular approach in our white paper:

Increased service life and optimum efficiency in partial load operation, with time-dependent replacement of AC/DC modules
Simplified maintenance and servicing, with condition monitoring via integrated condition monitoring functions
High availability of the power supply, as a failure of a rectifier module is effectively compensated or reduced
Increased availability of electrolysis cells, with module-based IGBT rectifier technology
Individual structure of the electrolysis unit in various sizes, with flexible topologies

Contact | Andreas Lautmann

Andreas Lautmann

Business Development Manager, Power-to-X

+49 5281 946-2720 alautmann@phoenixcontact.com

I would be happy to advise you on the way to a carbon-neutral future with green hydrogen.

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